Undercover for vehicles having high elasticity and rigidity and method for manufacturing the same

ABSTRACT

Disclosed are an undercover for vehicles with high elasticity and rigidity and a method of manufacturing the same. The undercover for vehicles with high elasticity and rigidity may include a needle-punched nonwoven fabric having a multi-layer structure of felt layers including a first PET fiber and a low-melting-point PET fiber, and each of the felt layers may have improved tensile strength and have optimized fiber alignment, to thereby improve the binding between fibers, mechanical rigidity and elasticity, as well as to reduce the weight of components, improve durability and secure harmlessness and inline workability.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims, under 35 U.S.C. § 119(a), the benefit ofpriority to Korean Patent Application No. 10-2019-0046575 filed on Apr.22, 2019, the entire contents of which are incorporated herein byreference.

TECHNICAL FIELD

The present invention relates to an undercover for vehicles with highrigidity that includes a needle-punched nonwoven fabric having amulti-layer structure of felt layers containing a PET fiber and alow-melting-point PET fiber, each having improved tensile strength, andhaving optimized fiber alignment, and a method of manufacturing thesame.

BACKGROUND

In the related art, an undercover is mounted on the bottom of a vehicle,and functions to protect components including an engine and atransmission installed in the underside of the vehicle. The undercoveralso functions to prevent foreign matter from entering the vehiclethrough the bottom of the vehicle while driving. In addition, theundercover plays an important role in absorbing and blocking noisegenerated from the vehicle, particularly, an engine and a transmission,and thereby preventing the noise from being transmitted to the outsideof the vehicle.

Conventional materials for undercovers include materials such aspolypropylene and glass-fiber-reinforced polypropylene composites.However, these materials have drawbacks of low fuel efficiency and poorNVH (noise, vibration, harshness) performance because of the excessivelyhigh weight thereof. In particular, the glass-fiber-reinforcedpolypropylene composites have associated problems of glass fiber dustand the disadvantage of low durability against external impacts.

In order to solve these problems in the technical field, polyethyleneterephthalate materials has been applied to manufacturing theundercovers. However, such polyethylene terephthalate materials haveless flexural rigidity than that of the conventional materials, and thusneed to be made more rigid in order to improve inline workability.

The above information disclosed in this Background section is providedonly for enhancement of understanding of the background of the inventionand therefore it may contain information that does not form the priorart that is already known in this country to a person of ordinary skillin the art.

SUMMARY

In preferred aspects, provided are an undercover for vehicles havinghigh elasticity and high rigidity due to the improved binding forcebetween fibers and a method for manufacturing an undercover for vehicleswhich may reduce the weight of components, improves durability, andsecures harmlessness (safety) and inline workability.

The objects of the present invention are not limited to those describedabove. The objects of the present invention will be clearly understoodfrom the following description and can be implemented by the meansdefined in the claims and combinations thereof.

In one aspect, provided is an undercover for vehicles having highelasticity and rigidity. The undercover may include a needle-punchednonwoven fabric formed by needle-punching a first nonwoven fabric layerincluding one or more first felt layers with a second nonwoven fabriclayer formed on the first nonwoven fabric layer and including one ormore second felt layers. Preferably, each of the first felt layer andthe second felt layer may include a fiber web including an amount ofabout 1 to 40% by weight of a polyethylene terephthalate fiber and anamount of about 60 to 99% by weight of a low-melting-point polyethyleneterephthalate fiber based on the total weight of the fiber web.

The first felt layer and the second felt layer may be the same ordifferent. The first felt layer and the second felt layer may be thesame, for example, having the identical components and contents thereof.The first felt layer and the second felt layer may be different, forexample, having at least one or more different components or havingdifferent contents of at least one or more components.

If the first and the second felt layers are different, suitably at leastabout 1, 2, 3, 4, 5, 10, 15 or 20 percent by weight of the first feltlayer composition is different from that of the second layercomposition.

Preferably, each of first nonwoven fabric layer and the second nonwovenfabric layer may include the first felt layer and the second felt layerwhich are laminated in a multilayer structure of two or three layersthereof. For example, each of first nonwoven fabric layer and the secondnonwoven fabric layer may include the first felt layer and the secondfelt layer which are laminated in a multilayer structure of two layersof the first felt layer and the second felt layer. Moreover, each offirst nonwoven fabric layer and the second nonwoven fabric layer mayinclude the first felt layer and the second felt layer which arelaminated in a multilayer structure of three layers of the first feltlayer and the second felt layer.

Each of the first nonwoven fabric layer and the second nonwoven fabriclayer may include fiber webs including the fibers of the first feltlayer and the second felt layer randomly mixed in horizontal andvertical alignments.

The first nonwoven fabric layer and the second nonwoven fabric layer maysuitably have a weight per unit area of about 300 to 750 g/m².

The first nonwoven fabric layer and the second nonwoven fabric layer maybe repeatedly laminated in a multilayer structure of three to fivelayers thereof. For example, the first nonwoven fabric layer and thesecond nonwoven fabric layer may be repeatedly laminated in a multilayerstructure of three layers, four layers, or five layers.

The polyethylene terephthalate fiber (“first polyethylene terephthalatefiber”) may suitably have a melting point of about 240 to 270° C., afiber length of about 48 to 76 mm and a tensile strength of about 3 to 4g/De.

The low-melting-point polyethylene terephthalate fiber may suitably havea melting point of about 105 to 180° C., a fiber length of about 48 to76 mm and a tensile strength of about 3 to 4 g/De. In any aspect, thelow-melting point polyethylene terephthalate fiber will have a meltingpoint that is at the temperature about 5, 10, 20, or 30 degrees lessthan the melting point of the first polyethylene terephthalate fiber.

The needle-punched nonwoven fabric may suitably have a weight per unitarea of about 600 to 1,500 g/m².

The number of times of needle punching of the needle-punched nonwovenfabric may suitably be about 20 to 80 punching/cm².

In another aspect, provided is a method of manufacturing an undercoverfor vehicles with high elasticity and high rigidity. The method mayinclude steps of: i) providing a first polyethylene terephthalate fiberhaving a melting point of about 240 to 270° C. and a low-melting-pointpolyethylene terephthalate fiber having a melting point of about 105 to180° C., ii) forming a fiber web by carding an amount of about 1 to 40%by weight of the first polyethylene terephthalate fiber and an amount ofabout 60 to 99% by weight of the low-melting-point polyethyleneterephthalate fiber based on the total weight of the fiber web, iii)forming each of a first felt layer and a second felt layer by bindingand hot-pressing the fiber web, iv) forming each of a first nonwovenfabric layer and a second nonwoven fabric layer by laminating the firstfelt layer and the second felt layer in two to three layers, and v)producing a needle-punched nonwoven fabric by laminating the secondnonwoven fabric layer on the first nonwoven fabric layer, followed byneedle punching.

The first polyethylene terephthalate fiber may suitably have a fiberlength of about 48 to 76 mm and a tensile strength of about 3 to 4 g/De.

The low-melting-point polyethylene terephthalate fiber may suitably havea fiber length of about 48 to 76 mm and a tensile strength of about 3 to4 g/De.

In the formation of each of the first nonwoven fabric layer and thesecond nonwoven fabric layer, each of the first nonwoven fabric layerand the second nonwoven fabric layer may be formed by repeatedlylaminating the fiber web in a multilayer structure of three to fivelayers.

In the producing the needle-punched nonwoven fabric, the needle-punchednonwoven fabric may suitably have a weight per unit area of about 600 to1,500 g/m².

The number of times of the needle punching in the producing theneedle-punched nonwoven fabric may suitably be about 20 to 80punching/cm².

Also provided is a vehicle including the undercover as described herein.

Other aspects and preferred embodiments of the invention are discussedinfra.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention will now bedescribed in detail with reference to certain exemplary embodimentsthereof illustrated in the accompanying drawings which are given hereinbelow by way of illustration only, and thus are not limitative of thepresent invention, and wherein:

FIG. 1 is a cross-sectional view showing an exemplary needle-punchednonwoven fabric of an exemplary undercover for vehicles according to anexemplary embodiment of the present invention; and

FIG. 2 shows a structure in which an exemplary fiber web of theneedle-punched nonwoven fabric according to the present invention arerandomly aligned in horizontal and vertical directions.

DETAILED DESCRIPTION

The objects described above, and other objects, features and advantagesof the present invention will be clearly understood from the followingpreferred embodiments with reference to the attached drawings. However,the present invention is not limited to the embodiments and may beembodied in different forms. The embodiments are suggested only to offera thorough and complete understanding of the disclosed context and tosufficiently inform those skilled in the art of the technical concept ofthe present invention.

Like numbers refer to like elements throughout the description of thefigures. In the drawings, the sizes of structures are exaggerated forclarity. It will be understood that, although the terms “first”,“second”, etc. may be used herein to describe various elements, theseelements should not be construed to be limited by these terms, which areused only to distinguish one element from another. For example, withinthe scope defined by the present invention, a “first” element may bereferred to as a “second” element, and similarly, the “second” elementmay be referred to as the “first” element. Singular forms are intendedto include plural forms as well, unless the context clearly indicatesotherwise.

It will be further understood that the terms “comprises” and/or “has”,when used in this specification, specify the presence of statedfeatures, integers, steps, operations, elements, components orcombinations thereof, but do not preclude the presence or addition ofone or more other features, integers, steps, operations, elements,components, or combinations thereof. In addition, it will be understoodthat when an element such as a layer, film, region or substrate isreferred to as being “on” another element, it can be directly on theother element, or an intervening element may also be present. It willalso be understood that when an element such as a layer, film, region orsubstrate is referred to as being “under” another element, it can bedirectly under the other element, or an intervening element may also bepresent.

Unless the context clearly indicates otherwise, all numbers, figuresand/or expressions that represent ingredients, reaction conditions,polymer compositions and amounts of mixtures used in the specificationare approximations that reflect various uncertainties of measurementoccurring inherently in obtaining these figures, among other things. Forthis reason, it should be understood that, in all cases, the term“about” should be understood to modify all numbers, figures and/orexpressions.

It is understood that the term “vehicle” or “vehicular” or other similarterm as used herein is inclusive of motor vehicles in general such aspassenger automobiles including sports utility vehicles (SUV), buses,trucks, various commercial vehicles, watercraft including a variety ofboats and ships, aircraft, and the like, and includes hybrid vehicles,electric vehicles, plug-in hybrid electric vehicles, hydrogen-poweredvehicles and other alternative fuel vehicles (e.g. fuels derived fromresources other than petroleum). As referred to herein, a hybrid vehicleis a vehicle that has two or more sources of power, for example bothgasoline-powered and electric-powered vehicles.

In addition, when numerical ranges are disclosed in the description,these ranges are continuous and include all numbers from the minimum tothe maximum including the maximum within each range unless otherwisedefined. Furthermore, when the range refers to an integer, it includesall integers from the minimum to the maximum including the maximumwithin the range, unless otherwise defined.

Throughout this specification, hereinafter, a first polyethyleneterephthalate (110 in FIG. 2 ) is referred to as “regular PET”, “firstPET”, or “PET”, and a low-melting point polyethylene terephthalate (120in FIG. 2 ) is referred to as “low-melting-point PET”.

In particular, the term “regular PET”, “first PET”, or “PET” as usedherein refers to a unmodified polyethylene terephthalate which typicallyhas a melting point in a range of about 230 to 280° C., or particularlyof about 240 to 270° C., or for example, or of about 250 to 260° C. Theterm “low-melting point polyethylene terephthalate” or “low-meltingpoint PET” as used herein refers to a polyethylene terephthalate whichis modified, for example, by incorporating different monomers such ascyclohexane dimethanolin the place of ethylene glycol monomer of thepolymer chain, so as to interfere crystallization of the PET anddecrease its melting temperature (melting point or “m.p.”). Preferredlow-melting point PET may have a melting point in a range of about 90 to200° C., of about 100 to 190° C., or particularly of about 105 to 180°C.

Hereinafter, various exemplary embodiments of the present invention willbe described in more detail.

The undercover material for a vehicle according to exemplary embodimentsof the present invention may include a single PET material, rather thanusing reinforcing fibers having high rigidity such as carbon fibers andglass fibers, which have been conventionally used for undercovers, butimproves rigidity and elasticity by adjusting the strength, content andfiber alignment of fibers to fall within optimum ranges.

The undercover for vehicles may secure mechanical strength by using afirst felt layer and a second felt layer including a regular PET fiberand a low-melting-point PET fiber, each having improved tensilestrength. Also, the strain (deformation) due to the load maybe minimizedby improving the internal binding structure of the felt layers, so theweight of components can be reduced and the durability can be improved.

In addition, a first nonwoven fabric layer and a second nonwoven fabriclayer, each including the first felt layer and the second felt layer,may be needle-punched, and the number of times of the needle-punchingmay be minimized, thereby optimizing the fiber alignment of regular PETand low-melting-point PET fibers and improving binding strength betweenfibers and elasticity. In addition, since the undercover for vehiclesmay contain only PET fibers and does not contain any glass fibers, itmay secure harmlessness and inline workability and is advantageous inthat PET may be easily recycled.

The present invention provides an undercover for vehicles including aneedle-punched nonwoven fabric formed by needle-punching a firstnonwoven fabric layer including a first felt layer and a second nonwovenfabric layer including a second felt layer formed on the first nonwovenfabric layer. Each of the first felt layer and the second felt layer maysuitably include a fiber web containing an amount of about 1 to 40% byweight of a regular PET fiber and an amount of about 60 to 99% by weightof a low-melting-point PET fiber, based on the total weight of the fiberweb.

FIG. 1 is a cross-sectional view of an exemplary needle-punched nonwovenfabric of an exemplary undercover for vehicles according to an exemplaryembodiment of the present invention. As shown in FIG. 1 , theneedle-punched nonwoven fabric includes a first nonwoven fabric layer150 and a second nonwoven fabric layer 160 formed on the first nonwovenfabric layer 150. Each of the first nonwoven fabric layer 150 and thesecond nonwoven fabric layer 160 may include the first felt layer 130and the second felt layer 140, which are laminated in a multilayerstructure of two or three layers. When the first felt layer and thesecond felt layer are formed into a multi-layer structure having greaterthan three layers, the horizontal alignment of the fibers in the feltlayer may be deteriorated and thus the strength may be reduced.

The first nonwoven fabric layer and the second nonwoven fabric layer maybe fiber webs in which the fibers of the first felt layer and the secondfelt layer are randomly mixed in horizontal and vertical alignments.Each of the first nonwoven fabric layer and the second nonwoven fabriclayer may include fiber webs in which regular PET fibers (e.g., 110 inFIG. 2 ) and low-melting-point PET fibers (e.g., 120 in FIG. 2 ) in thefirst felt layer and the second felt layer are horizontally aligned bycarding, and the horizontal and vertical alignments may be randomlymixed by needle punching.

That is, the needle-punched nonwoven fabric may minimize the physicalintermingling of fibers caused by needle punching when the horizontallyaligned first and second nonwoven fabric layers may be combined byneedle punching. FIG. 2 is a cross-sectional view showing an exemplarystructure in which exemplary fibers of an exemplary needle-punchednonwoven fabric are randomly aligned both horizontally and vertically.As shown in FIG. 2 , the needle-punched nonwoven fabric has advantagesof lower material deformation due to a load and less direction-dependentstrength difference when the fibers are aligned in horizontal andvertical directions, as shown in FIG. 2 .

The first nonwoven fabric layer and the second nonwoven fabric layer mayeach have a weight per unit area of about 300 to 750 g/m². When theweight per unit area of the first nonwoven fabric layer and the secondnonwoven fabric layer is less than about 300 g/m², productivity may bedeteriorated and cost competitiveness may thus be decreased. On theother hand, when the weight per unit area of the first nonwoven fabriclayer and the second nonwoven fabric layer is greater than about 750g/m², productivity may be improved, but physical properties may be lessthan desired. Preferably, the weight per unit area may be about 360 to650 g/m².

The first felt layer and the second felt layer include a fiber webincluding an amount of about 1 to 40 wt % of a regular PET fiber and anamount of about 60 to 99% by weight of a low-melting-point PET fiberbased on the total weight of the fiber web.

The first felt layer and the second felt layer may be formed throughrepeated lamination to form a multilayer structure of three to fivelayers. The fiber web having a weight per unit area of about 40 to 50g/m² may be produced by mixing the regular PET fiber withlow-melting-point PET fiber, followed by carding.

In addition, as the fiber web is laminated in a multilayer structure ofthree to five layers, the fibers of the regular PET fiber and thelow-melting-point PET fiber may be horizontally aligned to produce alightweight nonwoven fabric. In the present invention, a fiber webhaving a weight per unit area of about 40 to 50 g/m² is formed throughcarding and then multi-cross lapping, and a first felt layer and asecond felt layer can be formed in a multilayer structure by repeatedlylaminating the formed fiber web.

The regular PET fiber may have excellent heat resistance and may impartmorphological stability to the felt. The regular PET fiber may have amelting point of about 240 to 270° C., a fiber length of about 48 to 76mm and a tensile strength of about 3 to 4 g/De.

The low-melting-point PET fiber may improve the rigidity of the feltbecause of the excellent low-temperature adhesive properties thereof.Particularly, the low-melting-point PET fiber may contain an amount ofabout 20 to 50% by weight of a sheath layer containing a PET resin (1)modified so as to have a low melting point and an improved adhesiveproperty and an amount of about 50 to 80% by weight of a core layercontaining a (regular) PET resin (2). The PET resin modified so as tohave a low melting point and improved adhesive property (1) may have amelting point of about 105 to 180° C., and the regular PET resin mayhave a melting point of about 240 to 270° C. When the content of thelow-melting-point PET resin is less than about 20% by weight, adhesionnon-uniformity may occur, and when the content of the low-melting-pointPET resin is greater than about 50% by weight, excessive heat distortionand strength deterioration may occur.

When the content of the low-melting-point PET fiber is less than about60% by weight, the strength of the felt may be deteriorated. On theother hand, when the content of the low-melting-point PET fiber isgreater than about 99% by weight, the rigidity of the felt may beimproved, but when it exceeds a certain level, the material may beconverted to a brittle material that is easily broken and the strengthmay be deteriorated. The low-melting-point PET fiber may have a meltingpoint of about 105 to 180° C., a fiber length of about 48 to 76 mm and atensile strength of about 3 to 4 g/De. When the melting point of thelow-melting-point PET fiber is less than about 105° C., heat-resistantdurability may be deteriorated. On the other hand, when the meltingpoint is greater than about 180° C., moldability may be deteriorated.

Particularly, when the tensile strength of the regular PET fiber and thelow-melting-point PET fiber is less than about 3 g/De, the strength ofthe fiber may be weak and the flexural rigidity and flexural modulus maybe remarkably reduced. On the other hand, when the tensile strength ofthe regular PET fiber and the low-melting-point PET fiber is greaterthan about 4 g/De, physical properties may be deteriorated due to poor(defective) mixing of raw materials. Preferably, the tensile strengthmay be about 3.2 to 3.7 g/De.

The needle-punched nonwoven fabric may have a weight per unit area ofabout 600 to 1,500 g/m². When the weight per unit area of theneedle-punched nonwoven fabric is less than about 600 g/m², the strengthmay be insufficient for application to a wheel guard or an undercover.On the other hand, when the weight per unit area of the needle-punchednonwoven fabric is greater than about 1,500 g/cm², cost competitivenessmay be insufficient for application to a wheel guard or undercover, andweight reduction of vehicles may be inhibited. Preferably, theneedle-punched nonwoven fabric may have a weight per unit area of about1,100 to 1,300 g/m².

The number of times of the needle punching of the needle-punchednonwoven fabric may be about 20 to 80 punching/cm². When the number oftimes the needle punching is performed less than about 20 punching/cm²,it may be difficult to produce the needle-punched nonwoven fabricproperly due to insufficient binding force of the carded web. On theother hand, when the number of times of needle punching is greater thanabout 80 punching/cm², the alignment of the fibers is improved in avertical direction, and the amount of strain applied to the material dueto the load may increase. The needle-punched nonwoven fabric mayminimize the number of times needle punching is performed on the firstnonwoven fabric layer and the second nonwoven fabric layer compared to aconventional method, thereby reducing the material deformation (strain)due to the load.

In other aspect of the present invention, provided is a method ofmanufacturing an undercover for vehicles including: providing (e.g.,preparing) a regular PET fiber having a melting point of about 240 to270° C. and a low-melting-point PET fiber having a melting point ofabout 105 to 180° C.; forming a fiber web carding an amount of about 1to 40% by weight of the regular PET fiber and an amount of about 60 to99% by weight of the low-melting-point PET fiber based on the totalweigh of the fiber web; forming each of a first felt layer and a secondfelt layer by binding and hot-pressing the fiber web; form each of afirst nonwoven fabric layer and a second nonwoven fabric layer bylaminating the first felt layer and the second felt layer in two tothree layers; and producing a needle-punched nonwoven fabric bylaminating the second nonwoven fabric layer on the first nonwoven fabriclayer, followed by needle punching.

In the preparation of the regular PET fiber and the low-melting-pointPET fiber, the regular PET fiber may be produced through spinning,stretching and crimping processes so that the regular PET fiber may havea fiber length of about 48 to 76 mm and a tensile strength of about 3 to4 g/De. In the same manner as described above, the low-melting-point PETfiber may be produced such that the low-melting-point PET fiber has afiber length of about 48 to 72 mm and a tensile strength of about 3 to 4g/De.

In the formation of the first felt layer and the second felt layer, thefiber web may be laminated in a multilayer structure of three to fivelayers to form the first nonwoven fabric layer and the second nonwovenfabric layer.

In the production of the needle-punched nonwoven fabric, theneedle-punched nonwoven fabric may have a weight per unit area of about720 to 1,200 g/m².

In the production of the needle-punched nonwoven fabric, needle punchingmay be conducted by vertically moving a needle plate equipped withthousands of needles, wherein the number of times needle punching isperformed may be about 20 to 80 punching/cm².

Hereinafter, the present invention will be described in more detail withreference to examples. However, the following examples should not beconstrued as limiting the scope of the present invention.

EXAMPLE Example 1

A regular PET fiber was produced such that it had a melting point of250° C. and a fiber length of 64 mm. The low-melting-point PET fiber wasproduced such that it had a melting point of 180° C. and a fiber lengthof 52 mm. In addition, the tensile strength of the regular PET fiber andthe low-melting-point PET fiber was adjusted as shown in Table 1 below.

Then, 20% by weight of the regular PET fiber was mixed with 80% byweight of the low-melting-point PET fiber, followed by carding, to forma fiber web having a weight per unit area of 200 g/m². Then, the fiberweb was laminated in three layers, and was then hot-pressed at atemperature of 190° C. to form a first felt layer and a second feltlayer. The first felt layer and the second felt layer were eachlaminated in a two-layered multilayer structure to form a first nonwovenfabric layer and a second nonwoven fabric layer having a weight per unitarea of 1,200 g/m² and thereby produce an undercover for vehicles.

Examples 2 to 6 and Comparative Examples 1 to 12

Undercovers for vehicles of Example 2 and Comparative Examples 1 to 6were manufactured in the same manner as in Example 1 except that thetensile strength of the fiber was changed as shown in Table 1 below.

Undercovers for vehicles of Example 3 and Comparative Examples 7 and 8were manufactured in the same manner as in Example 1 except that themixing ratio of the regular PET fiber and the low-melting-point PETfiber was changed as shown in Table 2 below.

Undercovers for vehicles of Examples 4 to 6 and Comparative Examples 9to 12 were manufactured in the same manner as in Example 1 except thatthe laminate structure of the felt layers and the number of times ofneedle punching were changed as shown in Table 3 below.

Experimental Example 1 Evaluation of Physical Properties According toTensile Strength of Regular PET Fiber and Low-Melting-Point PET Fiber

The properties of the regular PET fiber and the low-melting-point PETfiber according to the tensile strength of the undercovers for vehiclesmanufactured in Examples 1 and 2 and Comparative Examples 1 to 6 wereeach evaluated twice. The results are shown in Table 1 below. At thistime, the tensile strength was evaluated in accordance with ASTM D5034,and the flexural strength and flexural modulus were evaluated inaccordance with ISO 178 A method.

TABLE 1 Regular Low-melting- PET point fiber PET fiber Needle-punchednonwoven fabric Tensile Tensile Tensile Flexural Flexural strengthstrength strength strength modulus Item (g/De) (g/De) (N) (N) (Mpa) Ex.1 3.2~3.7 3.2~3.7 2,063/2,114 28/25 1,403/1,107 Ex. 2 3.0~3.2 3.0~3.22,040/1,950 24/22 1,180/1,070 Comp. Ex. 1 2.5~2.7 2.5~2.7 1,636/1,82316/13 715/730 Comp. Ex. 2 2.5~2.7 3.0~3.2 1,830/1,810 19/18 875/823Comp. Ex. 3 3.0~3.2 2.5~2.7 1,965/1,716 19/17 980/745 Comp. Ex. 44.2~4.7 4.2~4.7 2,006/1,627 21/17 987/780 Comp. Ex. 5 4.2~4.7 3.0~3.21,991/1,875 22/21 1,105/1,050 Comp. Ex. 6 3.0~3.2 4.2~4.7 2,018/1,74723/22 1,080/1,113

The results shown in Table 1 show that, when, in Examples 1 and 2, thetensile strength of the regular PET fiber and the low-melting-point PETfiber fall within the range of 3 to 4 g/De, the tensile strength,flexural strength and flexural modulus of the needle-punched nonwovenfabric are excellent overall, and as the tensile strength of the fiberincreases, the rigidity and elasticity of the needle-punched nonwovenfabric increase.

On the other hand, the results of Table 1 show that, in ComparativeExamples 1 to 3, 5 and 6, the specific tensile strength ranges of theregular PET fiber and the low-melting-point PET fiber are allunsatisfactory, and the tensile strength, flexural strength and flexuralmodulus of the needle-punched nonwoven fabric are significantlydeteriorated.

Also, in Comparative Example 4, when the tensile strength of the fiberexceeds 4 g/De, the tensile strength of the needle-punched nonwovenfabric is maintained at an appropriate level, but the flexural strengthand flexural modulus of the needle-punched nonwoven fabric are decreaseddue to defective (poor) mixing of raw materials.

Experimental Example 2 Evaluation of Physical Properties According toMixing Ratio of Regular PET Fiber and Low-Melting-Point PET Fiber

The physical properties according to the mixing ratio of the regular PETfiber and the low-melting-point PET fiber of the undercovers forvehicles manufactured in Examples 1 and 3 and Comparative Examples 7 and8 were each evaluated twice, and the results are shown in Table 2 below.

TABLE 2 Regular Low- PET melting-point fiber PET fiber (wt %) (wt %)Tensile Tensile Needle-punched nonwoven fabric strength: strengthTensile Flexural Flexural 3.2~ 3.2~ strength strength modulus Item3.7g/De 3.7g/De (N) (N) (Mpa) Ex. 1 40 60 2,063/2,114 28/25 1,403/1,107Ex. 3 20 80 2,060/2,100 26/24 1,365/1,058 Comp. Ex. 60 40 1,744/1,50724/20 1,453/1,217 7 Comp. Ex. 80 20 1,470/1,060 12/9  730/548 8

The results of Table 2 show that, in Examples 1 and 3, the regular PETfiber and the low-melting-point PET fiber were mixed at a proper ratio,and that the tensile strength, the flexural strength and the flexuralmodulus were excellent overall.

On the other hand, in Comparative Examples 7 and 8, as the relativecontent of the low-melting-point PET fiber was decreased, the rigidityand elasticity were rapidly reduced due to insufficient adhesion betweenfibers.

Experimental Example 3 Evaluation of Properties According to LaminateStructure of Needle-Punched Nonwoven Fabric and Number of Times ofNeedle Punching

The physical properties according to the laminate structure of theneedle-punched nonwoven fabric and the number of times of needlepunching of the undercovers for vehicles manufactured in Examples 1 and4 to 6, and Comparative Examples 9 to 12 were evaluated twice, and theresults are shown in Table 3 below.

TABLE 3 Needle-punched nonwoven fabric First Second The non- non- numberof woven woven times of fabric fabric needle layer layer punchingTensile Flexural Flexural Felt layer Felt layer (punching/ strengthstrength modulus Item structure structure cm²) (N) (N) (Mpa) Ex. 1 3layers 3 layers 30 2,063/2,114 28/25 1,403/1,107 Ex. 4 2 layers 2 layers30 1,840/1,850 20/21 705/830 Ex. 5 3 layers 3 layers 80 2,000/2,05024/25 1,000/1,280 Ex. 6 2 layers 2 layers 80 1,820/1,850 19/20 700/802Comp. Ex. 9 3 layers 3 layers 90 1,872/1,926 23/25   935/1,188 Comp. Ex.10 2 layers 2 layers 10 1,700/1,705 17/18 710/980 Comp. Ex. 11 1 layer 1layer 30 1,564/1,497 17/18 699/817

The results of Table 3 show that the tensile strength, flexural strengthand flexural modulus of Examples 1 and 4 to 6 were all superior to thoseof the needle-punched nonwoven fabric according to the laminatestructure and the number of times of needle punching operations.

On the other hand, in Comparative Example 9, the number of times ofneedle punching was excessively high, for example, 90 punching/cm², andthe vertical alignment between the fibers was increased, so that thetensile strength and the flexural modulus were decreased compared toExamples 1 and 5.

In Comparative Example 10, the number of times of needle punching wasexcessively low, for example, 10 punching/cm², so that the bindingbetween fibers was deteriorated, and tensile strength and flexuralstrength were reduced compared to Examples 4 and 6.

In Comparative Example 11, the needle-punched nonwoven fabric includingthe first felt layer and the second felt layer, each formed as a singlelayer, had a relatively low tensile strength, flexural strength andflexural modulus due to the low horizontal alignment ratio of thefibers. Also, these physical properties did not satisfy the propertiesrequired for undercovers.

The undercover for vehicles according to various exemplary embodimentsof the present invention utilizes a first felt layer and a second feltlayer, each of which includes a regular PET fiber and alow-melting-point PET fiber and has improved tensile strength, therebysecuring mechanical rigidity, reducing the weight of components andimproving the durability thereof.

The undercover for vehicles according to various exemplary embodimentsof the present invention may include a first nonwoven fabric layer and asecond nonwoven fabric layer, each of which includes a first felt layerand a second felt layer, may be needle-punched and the number of timesneedle punching may be performed minimized, so that the alignment of theregular PET and low-melting-point fibers may be optimized, and thebinding between the fibers and elasticity maybe improved.

In addition, the undercover for vehicles according to various exemplaryembodiments of the present invention may not contain glass fibers at alland may include only a PET fiber, thereby securing harmlessness andinline workability and being advantageous for recycling PET.

The effects of the present invention are not limited to those mentionedabove. It should be understood that the effects of the present inventioninclude all effects that can be inferred from the description of thepresent invention.

The invention has been described in detail with reference to theexemplary embodiments thereof. However, it will be appreciated by thoseskilled in the art that changes may be made in these embodiments withoutdeparting from the principles and spirit of the invention, the scope ofwhich is defined in the appended claims and their equivalents.

What is claimed is:
 1. A method of manufacturing an undercover forvehicles with high elasticity and high rigidity comprising: providing afirst polyethylene terephthalate fiber having a melting point of about240 to 270° C. and a low-melting-point polyethylene terephthalate fiberhaving a melting point of about 105 to 180° C.; forming a fiber web bycarding an amount of about 1 to 40% by weight of the first polyethyleneterephthalate fiber and an amount of about 60 to 99% by weight of thelow-melting-point polyethylene terephthalate fiber based on the totalweight of the fiber web; forming each of a first felt layer and a secondfelt layer by binding and hot-pressing the fiber web; forming each of afirst nonwoven fabric layer and a second nonwoven fabric layer byalternately laminating the first felt layer and the second felt layer intwo to three layers; and producing a needle-punched nonwoven fabric bylaminating the second nonwoven fabric layer on the first nonwoven fabriclayer, followed by needle punching, wherein the first polyethyleneterephthalate fiber has a tensile strength of about 3 to 3.7 g/De, thelow-melting-point polyethylene terephthalate fiber has a tensilestrength of about 3 to 3.7 g/De, and the number of times of the needlepunching in production of the needle-punched nonwoven fabric is about 20to 80 punching/cm².
 2. The method according to claim 1, wherein thefirst polyethylene terephthalate fiber has a fiber length of about 48 to76 mm.
 3. The method according to claim 1, wherein the low-melting-pointpolyethylene terephthalate fiber has a fiber length of about 48 to 76mm.
 4. The method according to claim 1, wherein, in the forming the eachof the first nonwoven fabric layer and the second nonwoven fabric layer,each of the first nonwoven fabric layer and the second nonwoven fabriclayer is formed by repeatedly laminating the fiber web in a multilayerstructure of three to five layers thereof.
 5. The method according toclaim 1, wherein, in the producing the needle-punched nonwoven fabric,the needle-punched nonwoven fabric has a weight per unit area of about600 to 1,500 g/m².